Wall and wall unit construction



Feb. 5, 1957 R. R. suNDELxN ETAL 2,779,979

WALL AND WALL UNIT coNsTRuTIoN Filed March 16, 1955 2 Sheets-Sheet lf/f//P ATTORNEYS) Feb. 5 1957 l R. R. SUNDELIN ETAL 779,979

WALL AND WALL UNIT CONSTRUCTION Filed March 16, 1953 2 Sheets-Sheet 2ETE. T351@- T 29 34a A -a 30 30 3l /a 3l* 35a \/0c Eig-"fga A fig-1A C C|NvEN'ToRe ROA/AL l?. JUA/0.5L /v HAR FEDER 7745/1? ATTORNEYS WALL ANDWALL UNIT CONSTRUCTION Ronald R. Sundelin, Roslyn Harbor, and HarryFeder, New York, N. Y., assgnors to Barclay Manufacturing Co., Inc.,Bronx, N. Y., a corporation of New York Application March 16, 1953,Serial No. 342,384 6 Claims. (Cl. 20-15) This invention relates toimprovements in the construction of building walls, particularlyinterior walls, and to an improved wall unit or panel.

The general object of the invention is to provide a wall construction ofprefabricated units so constructed that they can be quickly assembledand attached to the studdi'ng, or other wall supporting structure.

Another object of the invention is to provide a prefabricat-ed wallconstruction having moisturepmof joints between the sections or panelsconstituting the wall units.

Another object of the invention is to provide a wall constiuction whichhas superior sound insulating as well as vapor sealing properties.

A further object of the invention is to provide a wall unit which isconstructed to provide moistureproof joints between adjacent units, whenthey are assembled to form a wall without the use of calking compound,or the like.

A still further object of the invention is to provide a wallconstruction wherein the joints between the sections thereof provide forexpansion `and contraction of the sections or units.

It will be understood that the term wall as used throughout thisapplication includes also the ceiling of a room, since the improved wallunits can be used for the construction of ceilings as well as sideWalls.

The invention will be understood from a consideration of theaccompanying drawings and the following detailed description. In thesedrawings:

Fig. l is a somewhat enlarged horizontal section of the improved wallconstruction taken on line 1-1 of Fig. 5;

Fig. 2 is a perspective view of a detail;

Fig. 3 is an enlarged cross section of one form of molding which formspart of the wall unit of the invention;

Fig. 4 is a greatly enlarged section of the joint shown at the left ofFig. 1 between two adjacent wall units;

Fig. 5 is a fragmentary front elevation showing the improved wallconstruction and drawn to a much smaller scale than the other figures;

Fig. 6 is a. view similar to Fig. 3 showing a modified form of molding;

Fig. 7 is a fragmentary sectional view drawn to the same scale as Fig. 6and showing the exposed portion of the joint between two wall sectionsemploying this form of molding;

Figs. S and 9 are views similar respectively to Figs. 6 and 7 showinganother modied form of molding;

Figs. l and ll .are also similar respectively to Figs. 6 and 7 showing afurther modified form of molding; and

Figs. l2 and 13 are similar views showing still another modified form ofmolding.

Referring now to these drawings, a wall unit, indicated generally byreference character A Iand made in accordance with the invention, isshown in front view in Fig. with portions of the adjacent units B and C,respectively, at left and right, but with the upper and lower portionsof all three units broken away. Fig. l shows these units in section,unit C, however, not yet being in position. The

vf nited States Patent l `means of suitable adhesive 12 (Fig. 4).

2,779,979 Patented Feb. 5, 1957 units are supported along their oppositevertical side edges upon a pair of upright studs 1. These are usually ofwood, two by four inches (2 x 4") and are usually spaced sixteen inches(16) apart. Accordingly, the wall unit or panel is customarily made tohave a width to span two studs. It, of course, can be made to span threeor more studs, if desired.

The wall units (of which unit A is typical, sh-own broken away at thecenter of Fig. l) are each composed of a rigid body member 2 and afacing sheet member 3. These two members are of equal width but aresecured together, by means of a layer of adhesive 4, in such a way as toleave a portion 5 of body member 2 projecting beyond one edge 6, forexample the left edge of facing sheet 3, and also leaving a portion 7 offacing sheet member 3 projecting beyond body member 2 along the oppositeor right-hand edge of the unit.

The body member 2 is preferably about three eights of an inch thick andthe facing sheet member 3 about one eighth of an inch (1/8 thick makinglthe overall thickness =of the unit approximately one half of an inch(1/2). These dimensions, however, can be varied to suit conditions. Thebody member 2 is preferably made of asphalt impregnated wood fiberinsulating board, although it can be made of plasterboard, asbestoscementboard, plywood, or the so-called sawdust boards, cellular plasticor rubber, and other materials of this general character. The facingsheet member 3 is preferably made of tempered compressed woodfiberboard, but it can also be 'made of glass or metal, or plastic, ifdesired. Advantageously, the `adhesive material 4, used to bond togetherthe two members 2 and 3, may be synthetic rubber latex. Other adhesives,however, may be used, such for example as a mixture of asphalt andreclaimed rubber, asphalt alone, or neoprene rubber latex.

The facing sheet member 3 is preferably provided with a suitable finishcoating 8. Advantageously coating 8 may be a synthetic baked enamel,such for example as an enamel made of alkyd and melamine resins, ormodified alkyd melamine resins. Such coating, however, may consist of anair-dried paint 0r of 'a sheet of suitable plastic material laminated tothe surface of facing sheet member 3, or the coating 8 may consist of asuitable lacquer. It will be understood, however, that the surface offacing sheet 3 may be left unfinished, and the wall painted in the usualmanner, after installation.

Extending vertically in the surface of body member 2 adjacent theleft-hand edge 6 of facing sheet member 3 there is a recess 9 withinwhich is mounted a molding,

indicated generally by numeral 10. Molding 10 comprises a flat base 11(Fig. 3) which is secured in recess 9 by Extending along the front ofbase 11 (and centrally thereof in the form of molding shown in Figs.l-4) there is an outwardly projecting .and generally rectangular rib orbead section 13 of yielding and resilient material and havingsubstantially flat and parallel opposite side portions 14 and 15", thepurpose of which will presently appear. Outwardly of the rib or beadsection 13 there is a cap section 16 having two laterally projectingwing portions 17 and i8 facing in opposite directions. These wingportions are also ilexible and resilient.

The molding 1t) is preferably made of vinyl plastic, extruded. It alsocan be made of natural rubber, or synthetic rubber such as neoprene, orof combinations of these materials, or of any convenient material whichwill provide the characteristics of exibility and resiliency in ribsection 13 and in wing portions 17 and 18.

When the molding 10 is mounted and adhesively secured in recess 9 asabove described, the extreme edge 6 of facing sheet member 3 projectsover a part of base 11 of the molding and into contact with theright-hand vertical surface 14 of the rib or bead section 13. Also, oneof the wing portions, for example the right-hand wing portion 17, isengaged by the edge 6 of facing sheet 3, which kedge is preferablycurved, as shown in the drawings. The engagement of edge 6 with surfaceid compresses rib section i3 somewhat, and its engagement with wingportion i7 forces the wing portion outwardly somewhat, as may be seen bycomparing Figs. 3 and 4. ln this way, a niostureproof and vaportightseal is formed throughout the height of the panel or unit.

The wall unit, therefore, comprises the body member 2, the facing sheetmember 3 and preferably also the molding ftd, these parts beingassembled and adhesively secured to one another as described. That is tosay, in order to obtain full advantage of the invention, the moldingforms a part of the prefabricated unit. This saves time in installationas it eliminates the calking oi' the joints between the wall units onthe job. However, if desired, the molding 10 may be put in place at thesito during the construction of the wall.

When a series of units are mounted on the studs l, or other wallsupporting means, to form a wall, the projecting portion 5 of bodymember 2 of each unit is placed eneath the projecting portion 7 offacing sheet member 3 of adjacent wall unit B, and its edge 19 (Fig. 4)engages the exposed vertical edge f5 of molding llt) attached to wallunit A. The two units are mounted sufficiently ciose to one another tocause the rib or bead portion i3 of the molding to be compressed orsqueezed somewhat. Also, the edge of the second wing portion 12B,opposite wing portion i7, is forced outwardly to some extent. Thissqueezing of the resilient molding 1i? between the edges of the facingsheets of the adjacent units produces effective moistureproof andvaporproof joints between them.

inasmuch as the two main elements of the units, namely, body member 2and facing sheet 3, are of the same width, and since the facing sheetsof adjacent panels are separated from one another by the width of therib portion i3 of molding 1), the ends 2i and 22 of the respectiveadjacent body portions 2 are separated from one another by a likedistance (Fig. 4). This leaves a space between these edges whichaccommodates the fas- Lening means by which the panels are attached tothe studs 1.

The wall units are not nailed directly to the studs but are attached bymeans of a particular form of Z-shaped metal clip 23 (Fig. 2). This clipcomprises a mid-section 25, a shank portion 26, and a toothed portionhaving a series of teeth 24. The teeth are tapered leaving spacesbetween them to facilitate application to the wall units. They arestamped from thin gage resilient sheet metal, with the shank and toothedlportion substantially parallel and projecting in opposite directionsfrom, and at right angles to, the central portion 25. Central portion 25corresponds in length to the thickness of body portion 2, and shank 26is arranged as shown in Fig. 2 to constitute a iiat spring, a singlenail hole 27 being provided near the outer end.

In mounting the panels on the studs 1, a series of these spring clips Z3are applied along the right-hand edge of a wall unit, for example wallunit A of Fig. 1, these clips being arranged on approximately a twelveinch spacing from the bottom to the top of the unit. In applying theclips to the unit the teeth 24 are worked into the joint between theouter surface of body portion 2 and the inner surface of the facingsheet 3. The teeth can be worked in by hand or driven in with -a hammerapplied to the end of the clip.

After these clips have been applied, `the wall unit is placed inposition. In doing this, projecting portion 5 of this panel A is workedin beneath the projecting portion 7 of the facing sheet 3 of thepreviously mounted panel B, in a manner to be described in detailpresently. The wall unit is held in place against the iight-hand studand vertically.

1, and a nail 28 is driven through the shank of each clip. The clipShanks 26 are long enough to place the nail holes 27 beyond the edge ofprojecting portion 7 of the facing sheet so that this projecting portiondoes not interfere with the driving of the nails.

This completes the mounting of the right-hand edge of the wall unit onthe stud, and leaves the exposed shank portions 26 of the spring clips23 bowed outwardly as shown in full lines in Fig. l and in dotted linesin Fig. 4.

The working of the left edges of each panel into place wili be describedin connection with the next unit, or panel C. The arrow at the right ofFig. l indicates this operation. In carrying it out, the ends of thespring clips 23 and heads of the nails 28 may cut shallow channels ordepressions in the inner surface of body member 2 allowing this surfaceto touch, or almost touch, the outer surface of the studding i, avoidingthe outward springing of the projecting portion 7 of the facing sheet ofthe previously mounted panel B. The spring action of the clip Shanks 26forces the outer surface of projecting portion 5 into close engagementwith the inner surface of the facing sheet projection 7, therebyproviding substantially tight joints between these two surfaces andreenforcing the joint formed between the molding lo and the edges of thefacing sheets of the two wall units.

As described, the panels are placed progressively in position from leftto right. Obviously, if desired, the facing sheet projecting portion 7can be arranged to project from the left of the panels instead of theright, in which case the assembly of the units would proceed in theopposite direction.

With this wall unit construction and mounting, expansion and contractioncan take place both horizontally Horizontal expansion and contractioncan take place because of the presence of the spaces between the edgesof the body member 2 in which the mid sections 25 of the spring clipsare positioned, and also because of the yielding and resilient moldingiii between the edges of the facing sheets 3 of the respective panels.The rib sections 13 and opposiing wing portions 17 and i8 of suchmolding can be squeezed to a greater extent, or to a lesser extent,without affecting the tightness of the joints or seal between thepanels.

Expansion and contraction can take place in the vertical directionbecause of the fact that the wall units are not directly nailed to thestudding but are indirectly secured through the medium ofthe springclips Z3, which can shift slightly with respect to the wall units andwith respect to the studding without affecting their ability t hold thewall units in place. Y

Referring now to the modified forms of molding shown in Figs. 6-13, itwill be understood that any of these forms can be used in place of theform of molding shown in Fig. 3. All live forms of molding have incommon the presence of a rib or bead section having substantially fiatand parallel opposite side'portions which are engaged and squeezed bythe edges of the adjacent panel sheets.

Thus in the form shown in Figs. 6 and 7, the rib or bead section is madeup of a central section 29 having on each side thereof two side sections30 which are biased to stand in an outwardly directed angular positionwith their inner edges out of contact with the sides of portion 29. Whenthe base 11a of molding 10a is mounted in its recess 9a, the right-handside section 3f) of the molding is forced against the right side ofcentral portion 29 by the edge of facing sheet 3a of the wall unit, asshown in Fig. 7. This leaves the left-hand side portion 30 projectingoutwardly as in Fig. 6, but when the panel is mounted in position, thefacing sheet projection 7a of the adjacent panel Vforces the left-handside portion 30 into symmetrical position. These side portions 30 areformed with protuberances 31, which with the surfaces ofy side sections30 of the rib or bead section 29 engages the edges of the two facingsheet portions 3a and 7a along'a partially straight and partially curvedsurface to provide the desired moistureproof joint.

In Figs. 8 and 9 the base member of the molding 10b is divided into twosections, a longer section 11b and a shorter section 32, and the rib orbead section is in the form of a nearly closed hollow square having legportions 53 and 34 which are joined together by an exposed portion 35.Leg portion 33 is formed integral with base member 1lb, and the basemember 32 constitutes a foot portion for the inner end of the oppositeleg portion 34.

When this form of molding is attached to a wall unit (Fig. 9) the legsection 11b is secured in the recess 9b by means of a layer of cement12b, the other base section 32, however, being left free and uneemented.Before such unit is mounted in position the leg portion 34 is adjacentto the left-hand wall of recess 9b, but after assembly in positionadjacent another panel the legs 34 and 33 and the exposed portion 35.3',forming the rib or bead section of this molding, are squeezed betweenthe edge of facing sheet 3b and the edge of facing sheet projection '7b.This not only produces the same effective moistureproof joint or sealbetween the adjacent wall units, but also causes the exposed portion 35to assume an arched or outwardly curved position as shown in Fig. 9, thematerial being both deformable and resilient. Thereby, an attractivemolding or beading of simple design between the panels is produced.

The molding 00 of Figs. 1G and 1l is similar to molding 10b, with theshorter base portion 32 omitted. The leg portions 33a and 34a arecompressed together by approximately the same amount and the exposedportion 35a arches in substantially the same manner, when two adjacentpanels are mounted in position and the molding is squeezed betweenopposing edges of the facing sheet 3c and facing projection 7c.

The form of molding 10d shown in Figs. l2 and 13 is also similar tomolding 10b of Figs. 8 and 9. The difference is that the base sections11d and 32a are symmetrical, the leg portions 33a' and 34d and theexposed portion 35h all being like the corresponding parts of themolding 10b.

When this molding is fixed in position on a panel, only the right-handbase section 11d is cemented to the walls of the recess 9d, theleft-hand base section 32a being left uncemented. When this panel ismounted in position adjacent to a corresponding panel, the legs 33d, 34dand exposed portion 35h are deformed in substantially the same manner asin the case of the molding 10b, as shown in Fig. 13.

It will be understood that all of these moldings can vbe made of any ofthe materials referred to hereinabove,

it being essential, however, that the material be both yielding orflexible, and resilient, in order that adequate pressure be producedbetween the contacting edges of the molding and the edges of the facingsheet members of the wall units. It will also be understood thatadditional changes can be made in the form and arrangement of themoldings and of the wall units, it being the intention that the scope ofthe invention shall be set forth in the appended claims.

I claim:

l. As an article of manufacture, a wall unit com prising a rectangularpanel member and a superposed facing sheet member substantiallycoextensive in area with said panel member, the contacting surfaces ofsaid members being adhesively secured together, said panel memberprojecting beyond said facing sheet member along one edge of the unitand the facing sheet extending beyond the panel member along theopposite edge of the unit, said panel member having a recess in theouter surface thereof on the same side as the facing sheet member andextending along the edge of the facing sheet, and a molding securedwithin said recess, said molding having an outwardly projectingcontinuous rib section of yielding resilient material, one side of saidrib section ertgagintT the edge of said facing sheet member.

2. A wall construction having a framework, a plurality of wall `unitssecured to said framework in juxtaposition, each unit having arectangular panel lmember and a facing sheet member adhesively securedthereto, said panel member having a portion projecting beyond the facingsheet along one edge of said unit and the facing sheet having a portionprojecting beyond the panel member along the opposite edge of the unit,said panel member having a recess in its outer surface extending alongthe edge of t-he facing sheet, and a molding seated within said recess,said molding having a continuous rib section of iexible resilientmaterial, one side of said rib section engaging the edge of said facingsheet, each o-f said wall units being secured to said framework alongthe edge of said panel member thereof which is adjacent the projectingportion of said facing sheet, and the projecting portion of the panelmember of the adjacent wall unit being disposed beneath said projectingfacing sheet portion, the edge of said facing sheet portion engaging theopposite side of said ilexible resilient rib section of said molding.

3. A wall construction as claimed in claim 2 in which the edge of thepanel member of each wall unit is secured to the framework by a seriesof spaced metal clips each clip having a shank portion lying against theframework and extending beyond the edge of the projecting portion of thefacing sheet and nailed to said framework.

4. A wall construction as claimed in claim 3 in which the shank portionsof the metal clips are formed as plate springs disposed between theframework and the projecting panel portions of the adjacent wall unitand urge the outer surface of said projecting portion against the innersurface of the projecting facing sheet member.

5. A wall construction as claimed in claim 2 in which the sides of therib section of the molding have oppositely projecting flexible resilientwing portions and one side of the rib section and its wing portionengage the edge of the facing sheet of the wall unit on which themolding is mounted.

6. A wall construction as claimed in claim 2 in which the molding has arib section whose surface is below the surface of the facing sheets.

References Cited in the le of this: patent UNITED STATES PATENTS1,676,076 Buchanan July 3, 1928 2,129,497 Horn Sept. 6, 1938 2,230,688Irwin Feb. 4, 1941 2,305,247 Fisher Dec. 15, 1942 2,381,469 Sweet Aug.7, 1945 2,708,016 Penton May 10, 1955 FOREIGN PATENTS 556,249 GreatBritain Sept. 27, 1943

